Fabrisonic’s Ultrasonic Addictive manufactured aluminum satellite heat exchangers

Fabrisonic’s Ultrasonic Addictive manufactured aluminum satellite heat exchangers

Fabrisonic LLC’s popularity has risen rapidly in recent times after the manufacturing of aluminum satellite heat exchangers. It is a manufacturer that deals with Ultrasonic Additive manufacturing Solutions. The headquarters are in Columbus, Ohio, in the United States of America. It utilized its SonicLayer 1200 metal addictive manufacturing machine to create satellite heat exchangers in recent times. The exchangers use 6061 aluminum and measures 100 by 114 by 15 mm. This project is under the Utah State University’s College of Engineering.

From reliable sources, it is clear that the Company has a wide range of experience in the production of satellite heat exchanges. It uses complex internal geometrics, which has completed NASA JET Lab’s testing criteria, which is harsh and powerful. In normal situations, heat exchangers usually use larger machines such as SonicLayer 7200. The Company initially used this method to come up with the 6061 aluminum satellite heat exchangers. However, this initial process was to test the SonicLayer 1200 ability to create complex channel geometrics.

The heat exchangers include complicated fluid passages. This invention is possible because CNC machined slots using the subtractive portion of the hybrid system. Later, experts filled the slots with patent-pending support material. When undergoing the post-cleaning process, you can eliminate the support material to maintain smooth and accurate fluid channels. After completing the internal channels, the creation process is almost done.

With a dimensionally accurate and smooth fluid channel, you build the part into a net shape. Later, you can machine the final dimensions in the right place. After achieving the right geometric dimensions and features that match the model, the following process is critical. It involves making sure that the heat exchanger is functional and leak proof. If the heat exchanger is functional with no abnormal features, you can test its performance on a satellite. It is also crucial to guarantee that the heat exchanger is hermetically sealed to avoid refrigerant leakage to the vacuum of space.

When testing the validation of these heat exchangers’ seals, experts submerge the units into a tub of water with the channels having a pressure of up to 50 psi. The development team looked for any bubbles that may escape from the heat exchanger’s channels to the water surface. If it was that case, then it is an indicator that the channels are not hermetic, and its vice-versa is also true. Fabrisonic’s production Company states that all the preliminary tests were well-run and complete. However, the team is looking forward to the final test taking place at Utah State University. These final tests will determine the performance of the small heat exchangers and their capabilities in space.